Cartoning machines and methods



Dec. 29, 1970 s. M. SILVER CARTONING MACHINES AND METHODS 4 Sheets-Sheet .1.

Filed Oct. 3, 1968 v Dec. 29, 1970 s. M. SILVER CARTONING MACHINES AND METHODS 4 Sheets-Sheet Filed Oct. 5, 1968 Dec. 29, 1970 s, V 3,550,345

CARTONING MACHINES AND METHODS Filed Oct. 5, 1968 4 Sheets-Sheet 3 Ln Ln [Rm w- FIG.4

Dec. 29, 1970 s. s R 3,550,345

CARTONING MACHINES AND METHODS Filed 00?. 5. 1968 '4 Sheets-Sheet 4.

United States Patent 3,550,345 CARTONING MACHINES AND METHODS Stanley Milton Silver, London, England, assignor to Keyolok Co. Inc., Dover, Del., a company of Delaware Filed Oct. 3, 1968, Ser. No. 764,904 Claims priority, application Great Britain, Oct. 9, 1967, 46,074/ 67 Int. Cl. B65b 43/26 us. (:1. 53-29 .24 Claims ABSTRACT OF THE DISCLOSURE BACKGROUND OF THE INVENTION This invention relates to a machine and process for erecting, filling and closing cartons (hereinafter and in the claims referred to simply as a cartoning machine and a cartoning process). 1 I v It is an object of the present invention to provide a cartoning machine and cartoning process by and in which cartons are subject to relatively short and compact linear movements and ar'closed while being moved, and which FIGS. 3 to 5 are fragmentary perspective views showing respectively a mechanism for transversely transferring a flattened carton to the upper track, the mechanism after having moved a carton to the upper track and also a carton-opening device, and a carton fully-opened to tubular disposition by a reverse folder;

FIG. 6 is a diagrammatic perspective view of a carton flap folding and sealing apparatus;

FIG. 7 is a perspective view of carton sealing flap folder bars;

FIG. 8 is a diagrammatic view of the filler hopper for charging cartons;

FIG. 9 is a diagrammatic perspective view of that end of the cartoning machine at which the cartons move downwardly from the upper track to the lower track;

FIG. 10 is a diagrammatic perspective view of a spring platform on to which the cartons land on their downward movement from the upper track;

FIG. 11 is a fragmentary perspective view of the horizontal guide rails and the mechanism for transversely adjusting same and also the mechanism for vertically adjusting the top horizontal rails; and,

are particularly suitable for medium' or short-run cartoning contracts and for operation skilled labor.

by. semi-skilled or nona cartoning machine comprising upper and lower carton guiding tracks, pusher conveying means for transporting along the upper track in one direction cartons delivered in open-ended condition, and during which conveyance the open bottom flaps of each carton are proces'sed'into a closed condition, means at one end of the tracks for permitting, or effecting, downwardmovement of the bottom-closed cartons from the upper track to the lower track, and pusher conveying means for transporting the cartons along the lower track in the opposite or return di rection and during which conveyance the open top. flaps of each carton are processed into a closedcondition.

Also according to the present invention there is provided a cartoning processcomprising the steps of conveying an open-ended carton along a first path andclosing the bottom of the carton during such conveying, subjecting the bottom-closed carton to a downward movement, conveying the bottom-closed carton along a second path parallel to and counter to said first path and closing the top of the carton during such conveying;

BRIEF DESCRIPTION OF THE DRAWINGS An embodiment of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1 is a carton flow diagram showing the principle of the cartoning machine and cartoning process in accordance with the present invention;

FIG. 2 is a diagrammatic perspective view of a carton magazine and carton stack advancing means; i

FIG. 12 is a fragmentary perspective view of the lower track and the lower conveyor of a compressing conveyor assembly and means for vertically adjusting same.

DETAILED DESCRIPTION OF THE INVENTION Before describing the cartoning machine and cartoning process in detail it is pointed out that for the sake of clarity all drives to the movable and operative components of the machine have been omitted.

It will be manifest that these drives can take a number of convenient and well known forms with the provision that they operate in a timed relationship which ensures the required sequence of operations in the machine and process. The drives do not, in fact, constitute part of the present invention.

It is visualized, however, that there will be along the length of the machine at its bottom a main drive shaft rotated by a single prime mover and that three vertical take-Off shafts will extend up from the main drive shaft, one at each end of the machine and one centrally of the ends of the machine. Drives can be taken from these shafts via gearing, sprockets-and-chains, pulleys-and-belts, cams, springs, singly or in combination or via any other drive transmission mechanism to operate the movable and operative components of the machine in the required timed sequence.

Reference is now made to FIG. 1 of the drawings. An essential feature of the machine is that the machine length is employed four times thus substantially reducing the machine length compared with existing cartoning the upper track 22 to the lower track 23, and there is a transverse carton transfer at 25 and 26 respectively from the magazine 20 to the upper track 22 and from the lower track 23 to the compressing conveyor assembly I 21. Carton flow in the machine is as indicated by the arrows, and it is to be noted that carton flow in the magazine 20 and lower track 23 is in the same direction while being in the opposite direction to carton flow in the upper track 22 and the compressing conveyor assembly 21.

A basic aspect of the machine is that it is provided with a number of fixed daturns which permit non-skilled adjustment of the machine to suit different carton sizes. Starting from the magazine 20 there is a transversely-adjustable, longitudinal vertical datum 27 defined by a plate which serves to ensure that cartons irrespective of size are presented to a carton-transfer mechanism to be described later with their side seam creases S always in the same position since the adjustable datum plate 27 brings the side edges SE of the cartons into varying positions depending on the width of the panels of the cartons. Thus, this side seam crease S acts in the manner of a fixed reference line. Next there is a transverse datum 28 constituted by a low friction plate for guiding a flattened carton from the magazine 20 to the upper track 22.

At the upper track 22 there is provided the main vertical datum 29 of the machine and constituted by a fixed longitudinal plate. The flattened cartons are opened to their open-ended tube disposition relative to this datum plate 29 and the back panels of the opened cartons are guided along the upper track 22 thereby. There are two further main datum lines 30 and 31 defined by fixed position horizontal rails and these co-operate respectively with the crease line CLl of the bottom closure flap of a carton in the upper track 22 and the crease line CL2 of the top closure flap of a carton in the lower track 23. It is to be noted that all transverse and vertical adjustments made to the machine for different carton sizes are effected relative to these horizontal datum rails 30 and 31. Finally, at the compressing conveyor assembly 21 there is a datum 32 for filled and sealed cartons which are aligned with the datum 32 in predetermined number before being advanced one step along the compressing conveyor assembly 21.

It is stressed that transverse and vertical adjustments of carton guiding components are effected relative to the horizontal datum rails 30 and 31 to conform with differently sized cartons and these adjustments will be described later in detail.

The cartoning machine will now be described in detail.

The magazine 21 (FIGS. 1 and 2) is constituted by an indexing rack 33 consisting of three parallel, longitudinally-extending chains 34 with their upper runs supported on a horizontal plate 35. Each chain 34 is supported by and engaged at each end with a gearwheel 36, only one shown, and the three gearwheels at the end of the rack 33 are carried by a common shaft 36. The chains 34 are operated by an asymmetrically pivotally mounted lever 37 which when stroked by a convenient drive engages a pitched gearwheel 38 carried on the shaft 36 at the transverse transfer end of the rack 33. Thus, for each lever stroke the chains 34 advance The lever 37 is connected by a spring 39 to a drive element 40 of the machine, which element 40 is actuated once each cycle of the machine. A spring-loaded pawl 41 prevents reverse rotation of the gearwheel 38.

A flat folded carton is always less than in thickness and it will therefore be manifest that there is always a certain amount of overdrive which is resilient due to the presence of the spring 39. This overdrive is made resiliently variable by any convenient arrangement, for example by providing a number of spring connecting points on the drive element 40 as indicated at 42.

The chains 34 detachably mount a pair of detachable pusher plates 43 (only one shown) which, each stepwise movement of the chains 34, advances a stack of flat folded cartons towards a fixed abutment plate 44. A transverse carton-transfer mechanism 25 is located between the leading carton of the stack and the plate 44.

The aforesaid resilient overdrive ensures that the leading carton of the stack is presented to the transfer mechanism with a consistent predetermined amount of backpressure which is necessary to ensure transverse transfer of the leading carton from the magazine 20 through an 4 escapement slot, which may incorporate a gate, to the upper track 22.

An operator, when the stack of cartons is reduced in length such as to require replenishment, simply disposes a further stack on the chains 34 behind the trailing pusher plate, removes the leading pusher plate 43 and re-locates it on the chains 34 at the rear of the fresh stack.

Two pusher plates 43 are provided to ensure that there is no loss of pressure on the carton stack when the leading pressure plate 43 is being re-located behind a fresh supply of flattened cartons.

As aforesaid, the longitudinal datum plate 27 provides lateral guidance for the fiow of the flat folded cartons and is position-adjustable to ensure proper presentation of differently-sized cartons as aforesaid to the transfer mechanism 25.

From the above it will be manifest that the cartons are stacked on the rack with the side seam crease S of each carton facing towards the center of the machine. This represents the three-ply section of the carton and therefore a line along which there is an essential area of pressure for carton manipulation.

The transfer mechanism 25 for moving the leading carton at any one instant will now be described with reference to FIGS. 3 to 5. It consists of a stroking arm or plate 45 slidable in top and bottom transverse guides 46 and 47, for a fixed stroke length, and is actuated by a lever, cam and spring device shown partially and generally at 48. A vertical plate 49 is connected to and carried by the stroking arm 45 and mounts on its cartonadjacent surface a pad of highest traction elastomeric material, for example silicone rubber, whereby its cartoncontacting surface has a glass-like smooth surface which appears to create a vacuum between the pad and leading carton presented to the pad with the correct amount of back-pressure.

As is mentioned above, the leading carton of the stack passes through an escapement slot incorporating a gate which consists of two vertically-spaced abutments 50 carried by the lateral datum plate 27 which are preset to ensure that only a single carton is transversely transferred at a time by the stroking arm 45. A mechanism generally indicated at 51 and of any convenient form is provided to permit fine adjustment of these gate abutments 50. The gate is not considered essential and may, if desired, be omitted.

The plate 49 and silicone pad are. connected to the stroking arm 45 by pivotal top and bottom links generally indicated at 52 connected by a bar 53 to which, in turn, is connected universally a connecting rod 45A secured to the stroking arm 45. This arrangement applies a wedging force to the plate '49 and pad. These links 52, or the bar 53 are acted on by stops (not shown) at each end of the stroke of the stroking arm 45. It will be manifest that any other convenient means may be employed to give the necessary wedging action.

Let us assume the stroking arm 45 is returning from the upper track 23 to pick up the next leading carton from the magazine 20. At the end of the return stroke the links 52, or rod 53, strike the stop and are moved to move the pad into wedge contact with the leading carton. The stroke arm 45 now moves to transfer the carton, still subject to wedge pressure of the pad, through the gate 50, or escapement slot if the gate is not provided, into the upper track 22, the carton being supported against the lowfriction plate 28 coated with or formed of polytetrafluorethylene. When the stroking arm 45 reaches the end of its stroke, which may be in fact of a length greater than that actually required correctly to position the carton in the upper track 22, say /8", the links 52 or rod 53 strike the stop and the wedging force of the pad on the carton is released during this overstroking. The leading edge of the carton strikes top and bottom abutments 54 and 54A at the end of the overstroking. This simultaneous action of overstroking and abutment striking tends to open the carton slightly and bring the side seam crease S into precise alignment with the longitudinal vertical datum 29.

It is important to note that the pad picks up each leading carton at the fixed reference line of its side seam crease S and releases same with the side seam crease S in alignment with the longitudinal vertical datum 29. i l

A carton-opening mechanism is provided at the longitudinal datum 29. It consists of a vertically-reciprocating bayonet 55 which performs all its work on the cartons at this datum line 29 and which is, for example,'cam actuated. The bayonet 55 has a width equal to the smallest depth carton which it is required to open and is mounted so that one of its side edges is substantially in line with the carton side seam crease S. The bayonet 55 has secured thereto at its top a plate 56 longer but narrower than the bayonet S and flared away from the bayonet 55 at the bottom as shown. The bayonet '55 and plate 56 reciprocate along a vertical guide track, part of which is indicated at 57, and which terminates a short distance above the top of the carton flaps to ensure accurate guidance of the bayonet 55 into the carton. On its downward movement the bayonet 55 enters the carton and the plate 56 retains the carton in position and restrains the carton from twisting once the bayonet 55 has entered same.

' Thecarton-opening mechanism also includes a folder plate 58 hinged as indicated at 59 in alignment with the datum 29. The folder plate 58 is alsocamactuated'(not shown) and it engages the face of the carton and pivots the face panel approximately 150, i.e. it reverse folds it when the bayonet '55 is in its down position. It is to be notedhere'that the plate '56 resists twisting of the carton suit different carton sizes and for this purpose they are carried by rods 74 secured to brackets 75 mounting pinions 76 meshing with chain elements or racks 77 on the vertical members 65. The pinions 76 are interconnected by a rod 78 to one end of which is secured a handwheel (not shown). Rotation of the handwheel, which is preferably calibrated, rotates the rod 78 and the pinions 76 which rotate up or down the racks 77 depending on the direction of rotation of the handwheel to raise or lower the rails 61 and 66 in synchronism.

The bottom rails 64 and 67 are also height adjustable, and the outboard rail 64 is connected by bars 79 secured to sleeves 80 slidable along vertical members 65. The rails 64 and 67 mounted between them a platform 81, which may be a belt, and this assembly of platform 81 and rails 64 and 67 is carried on a sub-chassis 82 having vertical screwed rods 83 screw-engaging'in sleeves or brackets 84 secured to a main chassis or framework 85 of the machine. These rods 83 have fast thereon pinions 86 drivingly connected by chains 87 to a calibrated handwheel 88.

Rotation of the handwheel 88 rotates the pinions 86 and screwed rods 83 thus vertically adjusting the sub-chassis 82 relative to the main chassis 85.

Thus, the top and bottom horizontal rails 61, 66 and 64, 67 are vertical adjustable relative to the horizontal datumrails and 31.

The cartons are conveyed along the upper and lower tracks 22 and 23 by pusher flights 89 secured to a driven endless chain 90 disposed in a vertical plane. It is preferred to use flights rather than pockets since the latter would require size adjustment to conform with carton size whereas the former requires no adjustment.

Before describing the processing of a carton as it travels through the upper and lower tracks 22 and 23 it is to be noted thatthe principal datums are the back panel of the carton which slides along the longitudinal vertical datum transversely" adjustable to accommodate-different carton widths. t r

Refe'renceis'now made to upper and lower tracks 22 and 23 and in particular to the carton guiding and conveying medhanisms. V Theupper and lower tracks 22 and .23 are defined by four vertically-spaced pairs, .of horizontal rails with .the

inner rail of each pair position stationary in a transverse direction and the outboard rail of each pair .movable transversely of the machine to vary the spacing between the rails-of each pairin accordance with carton size. The

and a handwheel (not shown) is connectedto one of the I screwed rods.70, whereby rotation of the handwheel will rotatethe rod-70 and its sprocket 71'tomove the chains 72 and so rotate the other sprockets 71 and rods 70 thus moving the outboard horizontal rails andvertical members inwardly or outwardly depending on the direction of rotationtof the handwheel. By this means, adjustment of the machine widthwise relativeto the datum rails 30 and 31is easily and readily effected and such adjustment can be carried out by" a semi-skilled or unskilled person by suitably calibrating the handwheel. Y I

It is tobe notedthat top rails 61, 66 are double rails witli springs 73 therebetween since these rails are subject not only to transverse but also vertical adjustment.

Thetop double'rails 61, 66 are vertically adjustable to plate 29, the crease line of the bottom closure flap which travels along datum rail 30 and the crease line of the top closure flap which travels along datum rail 31.

In the upper track 22, each carton is moved longitudinally by a pusher flight 89 which'engages' the lower portion of the carton, and with the top closure flaps each engaged between the rails of the corresponding double rails 66 and 61 and the crease lines of the bottom closure flaps travelling along rails 30 and 62-. Preliminary guide rails are preferably provided to guide the top flaps between the sections of the double rails.

It is to be noted here that the dust flaps of a carton are shorter in length than the closure flaps, i.e. the top closure flaps extend above the top dust flaps and the bottom closure flaps extend below the bottom dust flaps. This length differential is necessary to facilitate insertionof the bayonet into the flat carton for opening purposes, and to permit the top closure flaps to be engaged by their corresponding double rails.

As it travels along the upper track 22 the carton is bottom closed, sealed and charged. The tools employed are largely conventional save that they are split in two and the parts of each tool, if only transverse adjustment is required, are connected to the inboard and outboard rails. If also vertical adjustment had to be effectedpsprings would be provided between the tool parts.

It is to be noted here that all tools for acting on the carton top and bottom flaps are arranged between horizontal datum rails 30 and31 and their paired outboard rails. Thus transverse and vertical adjustments in addition to being effected relative to the datum rails are also effected relative to the working tools of the machine.

When the carton is opened out intotube form and its trailing side panel is engaged by the pusher flight 89 it is firstly acted on by a conventional forward tucking cam 91 which positions the trailing dust flap forwardly onto a stationary retaining member or ramp 92 which previously positions the leading dust flap rearwardly. The rust flaps are thus now horizontally disposed. Conventional plows 93 now flare the closure flaps outwardly to a horizontal disposition and the carton is now pushed over a glue applicator 94 which is rotated by any convenient means. After glue application the carton is moved to bottom closure flap folding bars shown in FIG. 7, the closure flaps taking up a vertical position again. These folding bars are automatically adjusted to suit different carton sizes when the outboard rails are transversely adjusted relative to the datum rails 30 and 31. There are two bars 95 and 96, both diagonally disposed relative to rails 30 and 62. The first bar contacted by the closure flaps is bar 95 which is pivoted intermediate its ends at 97 to datum rail 30, with a spring 98 connecting the tail of the bar 95 and the rail 30 to urge the bar 95 across the track 22 towards rail 62. The bar 95 is curved at its pivot remote end 99 to facilitate adjusting movement of the bar 95 when rail 62 is moved in or out, and movement of the glued closure flap therebetween. The second folding bar 96 is also pivoted to datum rail 30 at 100 and carries at its other end a pin 101 extending into an elongated slot 102 in rail 62. Thus, in advancing along track 22 the left hand glued closure flap is firstly folded up by bar 95 into contact with the dust flaps, the right hand glued closure flap passing between bar 95 and rail 62 and then the right hand closure flap is folded up by bar 96 into contact with the already-folded closure flap. The bottom closed carton is now deposited on a short roller track section 103 to hold the flaps in sealed relation.

It is to 'be noted that the height of the folding bars 95 and 96 in relation to the carton is determined by the datum rail 30 so that folding occurs at the bottom flaps crease line irrespective of flap length.

It will be manifest that if the dust and closure flaps required separation then cutters are provided before or at the forward tucking carn location.

Before describing charging of the bottom-sealed carton reference is made once again to the glue applicator. The glue applicator 94 has a circumferential dimension equal to the distance between three pusher flights, i.e. the diameter of the glue applicator 94 is equal to the distance between any two adjacent pusher flights. The linear speed of the applicator 94 is equal to that of a moving carton which permits simultaneous and registered pattern gluing at the north and south (top and bottom) cardinal points of the applicator 94 as can be seen in FIG. 6. The glue applicator 94 is, in fact, a wheel section equal in width to the width of the widest carton flap to be processed by the machine.

The printing plates of the applicator 94 are preferably heavily textured silicone rubber with a surface cellular pattern. The printing plates receive their glue from a single glue pot 104 of conventional design. The surface cells of the printing plates must hold suflicient glue for two glue stampings. In use, the arcuate printing plate lightly contacts the glue pot roller then transfers glue on to the top closure flaps of the bottom carton and then rotates and transfers glue onto the bottom flap of the top carton.

Back-up rollers (not shown) which are spring loaded are provided to press the closure flaps onto the printing plates. The spring-loading is such that on the first stamping there is light resilient pressure and on the second stamping heavy pressure, whereby all glue is evacuated from the surface cells of the printing plates.

While reference has been made to glue sealing of the cartons it will be manifest that other forms of closure may be effected, for example tongue-and-slot. The cartons may be tongue-and-slot or otherwise closed top and bottom or the cartons may be differently closed top and bottom, for example glue sealed at the bottom and tongueand-slot closed at the top.

Reference is now made to the charging of the bottom sealed cartons particularly with reference to FIGS. 6 and 8.

The carton charging apparatus comprises a position stationary supply bin or hopper 105 having an open top and bottom and a plurality of reciprocable filler hoppers 106, only one of which is shown for the sake of convenience. Each hopper 106 is disposed below the supply hopper 105 and is secured to a slidable plate 107. The filler hopper 106 is also open top and bottom and has in register with its open bottom a dispensing funnel 108 which is interchangeable so that different sized and shaped funnels can be employed for different sized cartons. The filler hopper 106 opens through the plate 107 as can be seen in FIG. 6. The filler hopper has an internal wall (not shown) which is position adjustable by a calibrated screw 109 to vary the volume of material to be charged into the cartons.

The plate 107 and filler hopper 106 are reciprocated by a crank and connecting rod 110. A shutter valve 111 is provided at the open bottom of supply hopper 105 and is operated by a solenoid 112 which is, in turn, operated by a micro-switch 113 actuated by the presence of a carton C. That is, no carton, no fill.

The filler hopper 106 slides along a valve plate 114 at its open bottom and plate 114 has adjustable trip controls 115 to provide for early or late opening of filler hopper outlet if desired.

Each filler hopper 106 moves at substantially the same speed as its corresponding carton moving along the roller track 103.

In use, the filler hopper 106 is reciprocated under the supply hopper 105 and if the micro-switch 113 is actuated by the presence of a carton C then the solenoid 112 is operated to open the shutter valve 111 and so allow filling of the filler hopper 106 during both the back stroke and forward stroke thereof. The material is, of course, prevented from passing out of the bottom of the filler hopper 105 by the valve plate 114. The filler hopper 106 is now moved forward excess product being wiped off by valve plate 114 and overlies the carton, an opening being provided in the valve plate 114, and the filler hopper 106 travelling at substantially the same speed of the carton C. The carton is thus filled from the tiller hopper 106 as it moves with the carton, the funnel 108 ensuring flow of the material into the carton. The weight of the material in the carton while it rides on the roller track section 103 assists in sealing the flaps together.

With a view to increasing the rate of throughput of the machine there may be provided more than say two filler hoppers 106 in tandem so that more than two cartons can be filled at the same time.

If it is desired to further increase the rate of throughput, i.e. to charge more than two cartons at a time, then a rotary turret type filler may be employed.

If necessary a dust extraction system may be provided at the charging end of the machine.

If the material to be packed is liquid or viscous then the cartons would be filled by any convenient arrangement while it is on the lower track 23 rather than on the upper track 22.

The charged carton is now moved off the roller track 103 by its pusher flight 89 onto a plate 116 which engages, say, about of the bottom edge of the carton and acts like a trapdoor. When the carton is located fully on the plate 116, the plate is withdrawn to permit downward gravitational movement of the carton. The plate 116 is withdrawn firstly from under the trailing end of the carton thus tending to give the carton a backward movement to compensate for the forward pushing movement of the pusher flight 89 whereby the carton drops linearly and lands substantially flat-bottomed. Two sides plates 117 and 11 8 provide lateral guidance for the carton as it falls. Guides 119 are provided between the forward edge of the plates 117 and 11 8 to ensure that the carton does I not fall forwardly out between the plates 117 and 118.

The plate 116 is activated by the pusher flight .89 which mechanically presses against a wheel mounted at the end of a shaft connected to the plate 116. This mechanism is not shown. The plate 116 may alternatively be cam-and-spring actuated.

The carton falls on to a spring loaded platform 120 (see FIGS. 9 and 10) between guide rails '64 and 67 and disposed at the lead-in end of the belt platform 81. The platform 120 is spring-loaded upwardly and its function is to gradually and progressively decelerate filled cartons of varying weights. To achieve this function the platform 120 consists of two vertically-spaced plates 121 and 122 connected at each end by scissor-fold members 124. The top plate 121 has a depending shaft 125 extending through a sleeve 126 in the bottom plate 122. These connections between the plates 121 and 122 ensure that the plates approach each other in a strictly parallel manner irrespective of where the weight of the carton lands on top of the plate 121. An adjustment screw 127 is provided at the pivot point of one of the scissor members 124 and three springs 128, 129 and 130 are connected between the screw 127 and the pivot point of the other scissor member 124. These three springs 128 to 130 represent three degrees of spring tension resistance, and the screw 127 permits tensioning as required. Only the lightest of the three springs, namely spring 128 is initially set to be taut and only by using the screw tensioner 127 does the second spring 129 and then the third spring 130 become taut.

The above-described platform 120 permits gradual and progressive deceleration so that the falling charged carton first engages the resistance of the weakest spring,12*8 thereby tensioning it and commencing deceleration. Thus, the spring resistance of the platform 120 to the falling charged carton can be pre-set in accordance with the known weight of the carton, with the platform 120 always returning to its horizontal alignment with the belt platform 81.

The adjustment screw 127 is preferably calibrated for ease of pre--setting of the platform spring resistance.

The spring-loaded platform 120 also has the secondary function of acting as a vibrator to settle the material in the carton. I i

In the machine there is one pusher flight 89 more than the number of cartons travelling along the upper and lower tracks 22 and 23' at any one time, and this free flight engages the carton located on the platform 120 at its top portion and pushes it on to the belt platform 81. The upper flap creases of the carton are aligned with the datum rail 31 and its paired rail 63 and as the carton is moved along the bottom track 23 by its pusher flight 89 the top flaps are folded, sealed and pass under a roller track section 131 identically as the bottom flaps were processed in the upper track 22. i

' Thus at the end of the lower track 23 the cartons are erected, charged and glue sealed top and bottom.

The belt platform '81 moves at the exact speed of the pusher flights 89 so as to provide a simple escapement of the cartons from the bottom track 23 on to the transverse conveyor 26 which transfers the cartons between adjustable guides variable to suit carton size on to the bottom plate conveyor 132 of the compressing conveyor assembly 21 which also consists of an upper plate conveyor 133.

It should be mentioned here that the bottom conveyor 132'is mounted on the sub-chassis 82 in horizontal alignment with the belt platform 81 so that it is vertically adjusted simultaneously with the latter.

The compressing conveyor assembly 21 is substantially conventional. The cartons are built up in face-to'back abutment and as they are pushed across the conveyor 132 the leading carton contacts and operates a push-bar which operates 'a micro-switch which actuates an electromagnetic clutch which connects a drive to the plate conveyors 132 and 133. These conveyors move the row of cartons. forward until they are clear of the push bar whereupon the clutch is disengaged and the drive discontinued. The conveyors 132 and 133 provide top and bottom compression to the cartons during the entire time that the glue is drying.

It is important to note here that due to the disposition of the magazine 20 above and at the same side of the machine as the compressing conveyor assembly 21 it is possible for a single operator to load the magazine with flattened cartons and to remove sealed and charged cartons from the conveyor assembly at substantially the same machine location.

Briefly, the sequence of the machine and process is that firstly a flattened carton is advanced stepwise along the magazine and is presented at the outlet of the magazine to a transverse transfer mechanism which moves the flattened carton to the upper track. The flattened carton at the inlet of the upper track is opened to open-ended tube disposition and is moved along the upper track where its bottom flaps are closed and sealed, with the carton then being sealed. The bottom-sealed and charged carton is then dropped on to the lower track and is moved therealong, its top flaps being closed and sealed. The charged and fully sealed carton is then moved transversely to the compressing conveyor assembly along which it is stepwise moved until the glue sets whereupon it is removed.

It is envisaged that transfer of the cartons downward ly from the upper track 22 to the lower track 23 may be other than gravitational. The cartons may be positively moved downwards by mechanical and/or fluid-operated and/ or electrically-operated mechanisms.

As a result of the present invention there is provided:

(a) a cartoning machine and process suitable for short or medium run cartoning operation whiclincan be operated by semi-skilled or non-skilled operatives since due to a simple but novel organization of fixed reference datums the carton guides and the operating tools can be adjusted to suit different carton sizes without the employment of skilled machine setters;

(b) a single chassis, multiple linear path machine of compact design which obviates or mitigates horizontal datum setting;

(c) a simple and quick size adjustment of the machine guides by even an unskilled person even when all three carton dimensions change;

((1) an automatic adjustment of the carton processing tools effected when the machine size adjustment is effected;

(e) the location of all carton operating or processing tools in relatively close juxtaposition.

I claim:

1. A cartoning machine comprising upper and lower carton guiding tracks, pusher conveying means for transporting along the upper track in one direction cartons delivered in open-ended condition, and during which conveyance the open bottom flaps of each carton are processed into a closed condition, means atone end of tha tracks for permitting, or effectini downward movement of the bottom-closed cartons from the upper track to the lower track, and pusher. conveying. means for transporting the cartons along the lower track in the opposite or return direction and during which conveyance the open top flaps of eachcarton are processed into a closed condition.

2. A machine'as claimed in claim 1, in which the tracks are defined by paired inboard and outboard horizontal guide rails disposed longitudinally along the length of the machine and in vertical spaced relationship, two of the inboard rails being position-stationary so as to define horizontal datumlines, and the outboard rails being interconnected such that they can be moved transversely of the machine in synchronism by common actuating means relative to the fixed horizontal datum lines so that different sized cartons can be accommodated in the tracks, and with tools for processing the carton flaps into closed position located between the fixed horizontal datum lines.

3. A machine as claimed in claim 2, in which each track is defined by two vertically-spaced pairs of paired inboard and outboard rails, the lower inboard rail of the top pair of paired rails and the top inboard rail of the bottom pair of paired rails constituting the fixed reference horizontal datum lines, and the uppermost and lowermost paired rails being vertically adjustable relative to the fixed horizontal datum lines to accommodate different sized cartons.

4. A machine as claimed in claim 1 comprising at the end of the upper and lower tracks opposite to that at which downward carton transfer occurs, conveying means for transferring the cartons transversely of the machine to a conveyor assembly consisting of upper and lower conveyors adapted compressibly to engage top and bottom of the cartons and convey them in the same directions as the cartons are conveyed along the upper track to a discharge location. I

5. A machine as claimed in claim 4, comprising a magazine for open-ended flattened cartons disposedin stacked relationship and disposed above the compressing conveyor assembly with the magazine in-feed substantially at the same location as the compresslng conveyor assembly outfeed, and means for moving the leadmg carton at any one instant transversely of the machine to the upper track.

6. A machine as claimed in claim 5, comprising means for advancing the stacked cartons in the same direction of movement as the cartons are conveyed along the lower track to present the leading carton of the stack to an escapement slot through which it is moved to the upper track.

7. A machine as claimed in claim 5, in which the magazine includes a transversely-adjustable vertical wall adjustable with the horizontal outboard guide rails to ensure that flattened cartons irrespective of size are presented accurately to the means for moving the cartons through the slot, which means comprises a stroking arm of fixed stroke length mounting a pad of high traction resilient material which grips each flattened carton at a side seam crease position and moves with the carton to the vertical reference datum of the machine.

8. A machine as claimed in claim 7, in which the resilient pad is carried by a mechanism which wedges it against the flattened carton to be traversed across the machine, and an abutment acting on said mechanism when the pad is in alignment with the vertical datum to release the Wedging action.

9. A machine as claimed in claim 6, in which the means for advancing the carton stack in the magazine is stepwise operable and includes a spring arrangement which ensures that the leading carton presented to the resilient pad is subjected to a predetermined amount of back-pressure suflicient to effect adherence between the carton and pad.

10. A machine as claimed in claim 7, in which the high traction resilient pad is formed of silicone rubber with a glass-like finish.

11. A machine as claimed in claim 5, comprising means at the upper track for opening the flattened cartons relative to a fixed reference vertical datum to open-ended tubular disposition for conveyance along the upper track.

12. A machine as claimed in claim 11, in which the means for opening the flattened cartons comprises a vertically reciprocable bayonet in alignment with the fixed reference vertical datum, a plate element secured to the bayonet to define a passage into which a wall of a flattened carton extends on downward movement of the bayonet and plate element, and a reverse folding device pivoted at the vertical datum to engage and pivot the face panel of the carton engaged by the bayonet through approximately 150 so as to cause the flattened carton to take up an open-ended tube disposition.

13. A machine as claimed in claim 2 comprising, between the vertically-spaced horizontal datum lines, forward tucking means and ramp means for urging and maintaining the bottom or top dust flaps of a carton to inward horizontal disposition, guide means for splaying the bottom or top closure flaps of a carton outwardly to horizontal disposition, a glue applicator means common to upper and lower tracks for applying glue to outwardlysplayed closure flaps of top and bottom cartons, folding means for urging the glued closure flaps, bottom or top, of a carton into adhering relationship with the corresponding dust flaps and each other, and means for bringing the flaps into pressure contact.

14. A machine as claimed in claim 13, in which the glue applicator means is a rotary adhesive applicator having an arcuate surface which travels at the identical linear speed of the carton conveying means in a circular path and the circumference of which is equal to the distance between three carton pusher conveying elements, whereby adhesive can be applied simultaneously to the flaps of two cartons, one in the top track and one in the bottom track.

15. A machine as claimed in claim 13 in which the folding means comprises a pair of longitudinally spaced folder bars diagonally-located and pivotally-mounted on each track with one folder bar resiliently loaded against a plate such that a transverse adjustment of the track automatically correctly position the folder bars for differentlysized cartons.

16. A machine as claimed in claim 1, comprising reciprocatory filler hopper means disposed above the upper track and movable with each carton during the period immediately after bottom sealing until immediately prior to downward transfer of the carton to the lower track, discharge of product from the filler hopper means into the carton occurring during this period as the filler hopper moves with the carton.

17. A machine as claimed in claim 16, in Which there is a plurality of reciprocatory filler hoppers movable with and counter to the carton at a speed substantially the same as the speed of the carton line.

18. A machine as claimed in claim 1, comprising a trapdoor at that end of the upper track remote from the magazine feed-in and openable to allow downward movement of the trailing end of the carton first to compensate for the forward pushing movement of its pusher conveying element so that the cartons land substantially flat bottomed on a platform at the inlet end of the bottom track.

19. A machine as claimed in claim 18, in which the platform is adjustable resiliently supported so that it can receive different weights of cartons in a shock-absorbing manner and return to a position in horizontal alignment with the bottom track.

20. A cartoning process comprising the steps of conveying an open-ended carton along a first path and closing the bottom of the carton during such conveying, subjecting the bottom-closed carton to a downward movement, conveying the bottom-closed carton along a second path aligned vertically below, parallel to and counter to said first path and closing the top of the carton during such conveying.

21. A cartoning process comprising the steps of conveying an open-ended carton along a first path and closing the bottom of the carton during such conveying, subjecting the bottom-closed carton to a downward movement, conveying the bottom-closed carton along a second path parallel to and counter to said first path and closing the top of the carton during such conveying, conveying flattened cartons along a third path parallel to and in the same direction of said second path, transversely conveying one flattened carton at a time from said third path to said first path, transversely conveying erected and closed cartons from said second path to a fourth path, and conveying and simultaneously compressing the cartons along said fourth path which is parallel to and in the same direction as said first path.

22. A process as claimed in claim 20, comprising the step of charging the carton after bottom closing and as it is conveyed along the first path.

'23. A cartoning process comprising the steps of conveying an open-ended carton along a first path and closing the bottom of the carton during such conveying, subjecting the bottom-closed carton to a downward movement, conveying the bottom-closed carton along a second path parallel to and counter to said first path and closing the top of the carton during such conveying, locating a fiattened carton at a fixed vertical datum at the first path and reverse folding the carton so that it maintains an openended tube disposition.

24. A process as claimed in claim 20 comprising the step of simultaneously applying adhesive to the bottom References Cited UNITED STATES PATENTS 2,762,274 9/1956 Kerr 53-374X TRAVIS S. McGEHEE, Primary Examiner E. F. DESMOND, Assistant Examiner US. Cl. X.R. 53186, 383 

